The key on the worm shaft is stuck in tight I gorund it down so I could remove the shaft without damaging the bushing. Left some meat but not much. With the shaft removed it's much easier to work on getting that key out.

If you have enough key left to get the edge of a chisel under, try tapping against the end of the key with a chisel and working it upward as you go. Should pop right out. (I know, that's easy for me to say.)

BigdogIf you can't fix it with a hammer, you've got an electrical problem.

Bigdogs solution usually works, but I had one a while back that I ended up taking to a machine shop and after several tries at conventional methods, he welded a small nut to the key so he could get a better grip on it. Between having the nut to get hold of, and the heating, it came right out.

Use a set of wire cutters to remove it. Most cutters have the blades at a slight angle to the handles. With the blades of the cutter parallel to the shaft, grab the end of the key tightly and then pry it out by pushing down on the handle. The slight angle of the cutters gives you a lot of leverage and the cutters hold the key tight. Works most every time.
Michael

If the key has been ground down as far as I think it has, neither the chisel or wire cutters will work.

Two more options:

- Use a center punch to drive one end down, forcing the other up. Then the chisel or wire cutters may take it out.

- Use a Dremel tool with a narrow grinding wheel. Cut a slice lengthwise through the center of it, until it will collapse together. Cut it completely into 2 pieces if necessary. Try not to hit the sides of the keyway, hitting the bottom a little shouldn't hurt anything.

I'm afraid to put too much heat on it as the shaft is hardened and I don't want to mess up the temper.

Donny, Mine was still sticking up, so it was easier to weld to, but a machinist welding a nut to the key won't produced enough heat to affect the shaft. However, if you want to do it yourself rather than taking it to a machine shop, JIm's suggestion of a Dremel type tool with a cutting wheel should work well.

Donny, I really doubt it is a hardened key. You wouldn't have been able to round it off with the side cutters and cut it with a chisel if it were. If it were hard, it would also damage the shaft if something went wrong and that would be a poor design. Take a file and if you can file it, it is soft.
Michael

I am certainly glad that you had success with the dremel. I am sure you
are aware of it but please wear safety goggles while using the dremel,
especially if it is a very high speed one. I use one all the time on my model railroad layout and on the tractor also. It sure makes haste out
of cutting off a stuborn nut. I usually use the "cut-off" wheels.

Since Country Elliott is rarely on the board, I want to step off into his
sales pitch. I have found that Kroil by Kano Labs works g-r-e-a-t on
loosening frozen/rusted anything that is supposed to move. I just
position the shaft with the keyway up and fill it with Kroil and let it
soak overnight. Pops right out with any of the drive, pry, punch methods
mentioned in above posts.